Precast Conc Floor System

ultrafloor
CONSTRUCTION INFORMATION
8.0 CONSTRUCTION INFORMATION

8.1
8.1.1
Support Structure Details

Ground Floor Construction
The Ultrafloor system provides a cost effective, durable and quality solution for ground floor
construction. The system is typically supported on Ultrafloor prestressed concrete bearers and
isolated piers internally with Ultrafloor bearers and engaged piers at external wall lines. Any load
bearing walls from floors above should be continued to ground.
Relevant design information for Ultrafloor bearers is contained in Section 7.3. The 170R bearer is
purpose made for ground floor construction to course easily with standard brickwork.
Some suggested methods of supporting Ultrafloor systems in ground floor situations are illustrated
below.
Figure 8.1.1a: Typical Ground Floor Bearer Detail

Ultrafloor is cost effective on sloping sites. Brickwork is minimised by using concrete bearers on
engaged piers at external wall lines and isolated piers and bearers internally.
ULTRAFLOOR TECHNICAL MANUAL
September 2002 Edition
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Figure 8.1.1b: Typical Ground Floor Balcony Detail

A neat verandah or balcony edge can be achieved by continuing the in-situ concrete topping over
the supporting brickwork and finishing with a small overhang and drip groove. Steps at verandahs
and balconies are easily achieved by adjusting the height of the support structure.
Figure 8.1.1c: Typical Ground Floor Ultrafloor Detail

Ultrafloor can be supported on 230mm brickwork at external wall lines. Slip joint material is not
usually required, as the precast beams do not bond to the wall. Load bearing walls over the slab
should be continued through to ground.
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8.1.2
Multi-Storey Construction
8.1.2.1
Introduction
Multi-storey construction can be divided into two broad categories:

1.
2.
Loadbearing wall construction

! Standard brickwork
!
Blockwork
Precast panels
Lightweight concrete (aerated)
Framed construction
!
Steel frames
In-situ concrete frames
Precast concrete frames
Concrete band beams:

-
Traditional
Flat plate concept
Ultrafloor systems are easily incorporated in either type of construction. The nominal seating for
the beams is given in Table 8.1.2
Table 8.1.2: Nominal Seating For Beams (mm)
Load Bearing Masonry
75
AAC & Low Strength Masonry
140
Concrete (precast)
60
Concrete (in-situ)
100
Steel
60
Ultrashell Bands
100
Bearers onto Piers
100
Some typical construction details follow:
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8.1.2.2
Loadbearing Masonry
The Ultrafloor system is typically supported on the internal skin of a cavity brick wall. The beams
can be lapped at internal brick walls. Plastic multiformers can be used to preserve fire and sound
insulation between compartments and to provide continuous bearing along the top of the wall.
Figure 8.1.2a: Typical Brickwork Support Detail

In general, concrete blockwork should be core filled prior to placement of the Ultrafloor beams
unless the bearing stresses on the blockwork are approved by a professional engineer. The fibrecement formboard can be set-down to the underside of the Ultrafloor beams and reinforcing bars
returned into the Ultrafloor topping slab to create a moment resisting joint. This detail is commonly
used for detention tanks and retaining walls.
Figure 8.1.2b: Typical Concrete Blockwork Support Detail

Aerated concrete walls require continuous bearing to reduce bearing stresses. Plastic multiformers
are used for this purpose.
8.1.2.3
Precast Walls
Construction utilising precast concrete walls and the Ultrafloor system can be extremely fast.
Various methods of connecting the Ultrafloor system to the walls exist, one of which is illustrated
below. It is important to provide adequate shear transfer at the connection either by providing
sufficient bearing to the Ultrafloor system, or by providing starter bars into the slab. Temporary
propping may be required during construction to provide shear transfer until the topping slab has
cured.
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Figure 8.1.2c: Typical Precast Wall Support Details

8.1.2.4
Steel Beam Supports
Steel beams must be designed in accordance with AS 4100 Steel Structures, or as a composite
section in accordance with AS 2327.1.
The Ultrafloor system can be easily incorporated into steel framed construction. Continuous
Ultrafloor slabs and composite steel beams allow for extremely efficient use of materials. A
suggested connection detail is illustrated below.
Figure 8.1.2d: Steel Beam Support Detail (Composite)

Steel beams are often used in elevated floors to provide support where no supporting walls exist.
Steel beams can also be used to reduce spans allowing the use of a lighter Ultrafloor system and
potential cost effectiveness. In many cases all or part of the steel beam can be incorporated within
the depth of the Ultrafloor system. Some typical examples are illustrated below.
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Figure 8.1.2e: Typical Steelwork Support Details 1
Figure 8.1.2f: Typical Steelwork Support Details 2
Figure 8.1.2g: Typical Steelwork Support Details 3

8.1.2.5
Reinforced Concrete Beam Supports
Precast and in-situ beams must be designed in accordance with AS 3600 Concrete Structures.
The Ultrafloor system can work compositely with the reinforced concrete beams to increase the
effective depth of beams. Some typical details are illustrated below.
Figure 8.1.2h: Typical In-situ Concrete Support Detail

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The reinforcing cage should extend under and adjacent to the Ultrafloor beam. The Ultrafloor beam
should be embedded into the reinforced concrete beam a minimum of 100mm.
Figure 8.1.2i: Typical Precast Concrete Support Detail

Ultrafloor can be supported on rebates cast into precast beams or on shelf angles fixed to the
precast beams.
8.2
Propping Requirements During Construction
One row of temporary propping at mid-span may be required during construction in order to control
deflection and to help support the construction loads. The maximum unpropped spans for each of
the systems is nominated in the span tables in Section 7.1.1. These span tables apply to standard
Ultrafloor systems with standard topping.
Propping may be required at shorter spans if additional topping concrete is to be placed (for
example in external areas). Propping lines should then be determined by a professional engineer
using the non-composite section capacities in Section 7.5.1. Details of construction design loads
are included in Section 7.2.
Typical arrangements for propping lines consist of a 100mm x 75mm timber header on Acrow
props at 750mm centre to centre. The propping arrangement must comply with all relevant codes
and regulations with adequate support at the base and horizontal ties as required.
Lines of temporary propping should not be removed within 3 days of the slab being poured.
Stacking of materials on the slab should not commence within 3 days of the slab being poured. All
materials should be stacked adjacent to available lines of support under the slab. Contact the
Ultrafloor technical department for advice on allowable stacking of loads if required.
The necessary lines of propping are indicated on Ultrafloor beam layout drawings.
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8.3
Trimming Voids / Saddle Supports
General Arrangements
Large voids and penetrations (ie over 450mm) within Ultrafloor slabs are achieved by trimming the
void with a structural steel saddle support. Steel saddles typically consist of angle or channel
sections spanning between two Ultrafloor beams across the void. Intermediate Ultrafloor beams
are supported on the steel saddle. The ends of the saddle are supported on the shoulder of the
Ultrafloor beams as shown in Figure 8.3a.
Figure 8.3a: Saddle Supports

Refer to Section 7.7.1 for guidance on their structural design. It should be propped during
construction. A grouping of two Ultrafloor beams is often required at each end of the saddle. In
cases where two Ultrafloor beams are insufficient to support the load concentration, structural steel
beams are required parallel to the Ultrafloor beams as in Figure 8.3a. Note consideration should be
given to placing re-entrant corner reinforcement to reduce likelihood of cracking in concrete.
Manufacture and Supply
Ultrafloor usually allow for any known saddles at the time of quotation. In this case, Ultrafloor
manufacture and supply the saddles at time of installation. Saddles allowed for are marked on the
Ultrafloor beam layouts.
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8.4
8.4.1
Topping Slab Considerations

Reinforcement Laps / Steel Fixing
Lapping of Shrinkage Control Mesh

It is suggested that the mesh be lapped using the following methods:
Case (a) Cross-wires have the same spacing.

Spliced-wire overhang small.
The two outermost wires of A overlap the two outermost wires of B.
Case (b) Cross-wires have same spacing.
Spliced-wire have usable overhang.
The two outermost wires of A overlap the two outermost wires of B, but the overhangs do
not contribute.
Case (c) Cross-wires have differing spacing.
Spliced-wire overhang not significant.
The two outermost wires of A overlap the two outermost wires of B, but the overhangs do
not contribute.
The following method is not acceptable:
Case (d) Cross-wires have differing spacing.

Spliced-wire overhang not significant.
The two outermost wires of A have not overlapped the two outermost wires of B, the
overhangs do not contribute, and the splice is NOT CORRECT.
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8.4.2
Stair to Ultrafloor Connection
In-situ and precast concrete stairs can be tied into Ultrafloor slabs in a similar manner to
conventionally reinforced slabs. Provision needs to be made however for the anchorage of
reinforcement into the slab. Generally, the fibre-cement formboard needs to be set down to the
underside of the Ultrafloor beams at the slab/stair junction. This provides in-situ concrete for the full
depth of the slab for anchoring top and bottom reinforcement from the stairs.
Common methods of connection are detailed below and in Section 10.C.7
1.
Beams in line with stairs support wall under
Figure 8.4.2a: Typical Stair Detail

2.
Beams in line with stairs saddle support and tang bars.
Figure 8.4.2b: Typical Stair Detail
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3.
Beams in line with stairs saddle support with holes.
Figure 8.4.2c: Typical Stair Detail
8.4.3
Wet Areas & Finished Floor Level Set-Downs
Set-downs in the finished floor level are often required for wet areas, waterproofing and tiling. Any
reduction in the depth of topping concrete over the Ultrafloor beams will affect the composite
strength of the slab in that area. Designers must be aware of this implication and make allowances
accordingly or contact the Ultrafloor Technical Department for advice on this matter. Techniques
for achieving finished floor level set-downs and allowing for them in design are outlined in this
section.
1.
A common technique is to provide local falls around the drains only. The depth of tile and
screed is balanced with the depth of carpet and underlay meeting the wet area. This detail as
in Figure 8.4.3a has minimal influence on the composite strength of the slab.
Figure 8.4.3a: Typical Wet Area Detail
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2.
The depth of the topping concrete over the Ultrafloor beam can be reduced provided
allowance is made for the strength reduction by the designer. The designer is able to model
the composite slab with any depth of topping. In cases where the topping slab is finished
flush with the top of the Ultrafloor beam, the slab should be modeled as a series of noncomposite beams (composite action is ignored). To maintain fire and sound insulation the FC
formboard is set-down to the underside of the Ultrafloor beams. The shrinkage mesh is cut
and placed between the Ultrafloor beams at the level of the shoulder. A flexible tanking
material should be used to prevent the propagation of shrinkage cracks into the tiles. See
Figure 8.4.3b.
Figure 8.4.3b: Typical Wet Area Set-Down Detail

3.
The system may be set-down as a whole in the wet area. The support structure levels also
need to change to provide this detail.
4.
Mixing different Ultrafloor systems of different depths can be used to provide set-downs as
detailed in Figure 8.4.3c. Each system is analysed separately for the imposed loading and
spans.
Figure 8.4.3c: Typical Set-Down Detail with Mixed Ultrafloor Systems
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8.5
Concrete Quality & Curing
GUIDANCE NOTES TO AVOID NON STRUCTURAL CRACKING IN CONCRETE

The factors affecting concrete and the properties of concrete tend to be variable.
Concrete is liable to crack in both the plastic and hardened state due to stresses, which it
intrinsically sustains by nature of its constituent materials.
The higher the water content in the concrete, the greater the tendency to shrink upon drying.
Ignoring the presence and effect of admixtures for a moment. a high-slump concrete will have a
greater tendency to crack than a low-slump concrete.
There are four main types of non-structural cracking:
i)
Plastic shrinkage
ii)
Early thermal contraction
iii)
Long-term drying shrinkage
iv)
Crazing
The period of time when these types of cracks appear are:

!
Plastic shrinkage occurs in the first few hours after pouring concrete.
Thermal contraction occurs from age one day and for up to two to three weeks.
Drying shrinkage occurs over several weeks, although continuing slowly for many years
thereafter.
Crazing is the phenomenon of cracking of the surface layer of concrete due to rapid loss of
moisture in hot or windy conditions, and is dependent on environmental conditions that are not
necessarily affected by time.
Prevention of Cracking
Wet down the FC formboard and beams in full before placing concrete. Use low-slump good
quality concrete. The concrete slump should be not greater than 85mm.
Cure properly: Preferably with a polythene sheet adequately tied down and covering the whole
area of the floor.
Ensure that joints are correctly installed.
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Curing Types of Curing Methods

Wet Cure:
i)
Pond water over the entire surface;
ii)
Completely cover the slab with hessian and keep continually damp;
iii)
Completely cover the slab with polythene sheet;
Spray-Applied Curing Compounds

Spray-applied curing compounds are available and should be applied as soon as the concrete has
lost its free water.
There is research evidence, however, to suggest that curing compounds are never as effective as
water- or damp-curing techniques.
Remember the more extreme the climate conditions (eg high temperatures and or windy
conditions), the greater care needs to be taken to ensure that the above problems do not arise.
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8.6
Control Joints
8.6.1
General Considerations
Control joints are introduced into slabs and other building elements as a means of controlling
cracking due to shrinkage, creep and temperature effects. The project engineer should generally
be responsible for determining the location of slab control joints as they have a detailed knowledge
of the overall building including the location of any construction joints, floor finishes, degree of
crack control required, etc. The following sections provide methods for detailing control joints in
Ultrafloor slabs.
8.6.2
Movement Joints
Movement joints are used to absorb any expansion or contraction within a slab due to temperature
and shrinkage effects.
!
The following guidelines may form the basis for positioning movement joints:
In internal situations, the maximum spacing of movement joints should be approximately 30

metres.
In external situations, the maximum spacing of movement joints should be 4-6 metres.
Ideally, joints should be placed at re-entrant corners, over lines of support and at changes in beam
direction.
Refer to Section 10 Typical Drawings and Standard Details for movement joint details.
8.6.3
Crack Control Joints
Crack control joints (tooled or saw cut) are used to weaken the concrete along a predetermined
line to force cracking to occur within the joint. Cuts should extend through the topping slab
sufficient to cut the reinforcement. The cut should be filled with expansive waterproof filler.
The maximum spacing of crack control joints should be approximately 10 metres. Re-entrant
corners and changes in direction of Ultrafloor beams are good places to position joints.
8.6.4
Construction Joints
Construction joints are introduced when the amount of concrete to be placed in one pour is limited.
At a construction joint fresh concrete is placed against hardened concrete. Ideally they should be
placed unobtrusively where any changes in texture or colour across a joint will not be noticed.
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8.7
Tiling over Ultrafloor
Special measures should be taken when large areas are to be tiled in respect to:
a)
Controlling shrinkage and negative moment cracking;
b)
Negative moment cracking;
c)
Joints in tiling;
Cracks in (a) above are normally non-structural and due to poor curing. However, steps can be
taken to ensure that shrinkage cracking is avoided by following the guidance notes in Section 8.5.
In addition, a heavier mesh (preferably with a deformed ribbing on the wires of the mesh), such as
SL62 or SL72 placed on 20mm chairs off the tops of the beams, will assist further in avoiding
cracks.
Negative moment cracks occurring above supports and bearers can be avoided by placing loose
deformed bars over the support, and tied into the chaired mesh.
Joints mentioned in (c) above should be provided in accordance with the appropriate Australian
Standard for the tiles being used.
It is important that the slab surface has not been contaminated with a curing compound that will
affect the bond between the tile adhesive and the concrete slab. Curing with polythene sheeting
and wetting down for the first three days will achieve the best results.
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8.8
Suspended Ceilings
Suspended ceilings can be fixed to the soffit of the Ultrafloor system by a number of proprietary
methods, depending on whether a resilient-mounted ceiling system is required or not for acoustic
insulation purposes.
The MASBOLT TRAKFAST Ceiling Suspension System has been developed in consultation with
that manufacturer to provide a cost effective solution to fix and support suspended ceilings.
MASBOLT provides a complete range of ceiling suspension anchor systems to meet the
requirements of any application. Benefits are:
!
The installation time per fix is a few seconds. No drilling is required. Labour costs are thus
greatly reduced.
The gas-powered TRAKFAST tool requires no special training or licence to use.
The system emits little noise or pollution and requires little maintenance.
TRAKFAST can be used to rapidly fix dry-wall tracking or clips to walls.
The system has been thoroughly tested to conform to AS 2788 Light Ceilings and test reports
are available from the manufacturer upon request.
Simple clip assembly allows any type of suspension system to be used.
Masbolt offers an on-site testing service, giving peace of mind to the installer and engineer
alike.
Where the TRAKFAST system is not appropriate, Masbolt can supply alternative specialised
suspension anchors to suit the projects needs.
See Figure 8.8a for typical details.
Figure 8.8a: Typical Suspended Ceiling Detail
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8.9
Building Code Provisions
8.9.1
Protection Against Termites
8.9.1.1
Clearance to Underside of Flooring
AS 3660.1 1995 Protection of buildings from subterranean termites requires that adequate
provision be made for visual inspection of sub-floor areas. Access for visual inspection shall
include a minimum clearance of 400mm between finished ground level and any structural
components. On sloping sites, the minimum clearance may be reduced to 150mm provided that
400mm clearance is provided within 2m.
8.9.1.2
Termite Barrier Details
Ultrafloor accept no responsibility for the termite protection of buildings. Whilst methods of
protection are outlined below, guarantees should be obtained from quality pest control companies.
Termite barriers should be installed at any point where termites may gain entry to a building. This
includes all slab penetrations, discontinuities and of course the slab perimeter.
The termite barrier should be cast into the slab just over the beams, draped across the cavity if one
exists and be built into the outer masonry wall. It should finish flush with the outside face to ensure
a complete seal against termite entry. The mortar joint in which the barrier is placed shall be at
least 75mm above finished ground level or paving. The barrier shall extend through the wall with
the edge being visible in the horizontal mortar joint at the outside face.
Any pipes or conduits penetrating the slab shall be provided with flanges.
Refer to Section 10 Typical Drawings and Standard Details for termite barrier details.
8.9.2
Thermal Insulation
The thermal resistance of Ultrafloor was evaluated by Solarch Energy Services in August 1995.
The thermal heat loss was measured using a guarded hot box calorimeter and thermal
transmittance was determined for interior and exterior temperatures of approx. 25C and 10C for
high and low under-floor ventilation rates. The results are presented in Table 8.9.2.
Table 8.9.2: Thermal Resistance of Ultrafloor System
Thermal Transmittance
2
(W / m K)
Thermal Resistance
2
(K m / W)
- low under-floor ventilation
3.68
0.272
- high under-floor ventilation
4.03
0.248
Ultrafloor with under-floor convection

barrier (suspended ceiling)
2.34
0.427
1.44
0.694
Flooring Configuration
Basic Ultrafloor
Ultrafloor with under-floor insulation

between beams
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8.9.3
Fire & Sound Separation
The properties of the Ultrafloor system with respect to fire and sound are given in Section 5 and
Section 6 respectively.
Fire separation between units with precast or masonry walls is readily achieved by using
Ultrafloors standard multiformers to set the in-situ concrete down onto the top of the wall as shown
in Figure 8.9.3a.
Figure 8.9.3a: Use of Multiformers for in-Situ Fire Separation
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Where a firewall runs parallel to the Ultrafloor beams (eg a corridor wall), Ultrafloors system of setdown can be used as shown in Figure 8.9.3b.
Figure 8.9.3b: Use of Set-Downs for In-Situ Fire Separation

Fire Collars
A wide range of fire collars is available for installation in the in-situ topping. The fire collars are
fixed to the fibre-cement formboards having set out the beams to suit the services. It is important to
expose at least 25mm of this fire collar beyond the pipe diameter as shown in Figure 8.9.3c.
Figure 8.9.3c: Use of Fire Collars for In-Situ Fire Separation
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8.10 Safe Installation Work Procedures

For full details of Ultrafloors safe working procedures, refer to the Site Installation Training Plan,
which is issued to all installers prior to work commencing. The following items, however are
covered in this section:
8.10.1
1.
Labour
2.
Documentation
3.
Access (cranes and trucks)
4.
Ultrafloor Beams
5.
Fibre-Cement Formwork Sheet
6.
Cranage
7.
Placing of Beams
8.
Beam Layout
9.
Installation
10.
Mesh Reinforcement
11.
Working Underneath
12.
Propping
13.
Set-Down Clips
14.
Multiformers
15.
Steelwork
16.
Penetrations
17.
Casting In-Situ Topping Concrete
18.
Stacking Materials on Slab
19.
Off-Loading Materials onto the Ground
20.
Handing over the Ultrafloor Deck
Labour
All installers must have site experience and have initial training in the installation of the
Ultrafloor system before installing beams on site. Training is available on request, otherwise a
new installer should be placed with an experienced crew.
All installers must have a current Green Card (OH & S induction training).
All installers must wear hard hats, appropriate footwear and comply with any other specific site
safety requirements.
The installation team shall be a minimum of 2 site workers and at least one should have a
riggers or dogman ticket.
The crane crew must have a dogman.
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8.10.2
Documentation
The following documentation is required on site prior to commencement of work:

-
Support Layout Plan
Beam Layout Plan
Cutting Schedule
Installation Checklist
The position of the beams on the building is indicated on the Beam Layout Drawing. The
drawing shows beam types, direction, lengths and mark numbers. The mark numbers indicate
the type and length of the beam. For this information, refer to the cutting / delivery schedule
which is always with the truck driver. The ends of the beams are marked with the mark number.
Where the Beam Layout Plan shows multiple beams placed under concentrated loads, care is
required to ensure they are located in the correct position.
8.10.3
Access (Cranes and Trucks)
Check the site for access and agree with the builder for crane and truck positions. It may be
necessary to get advice from a crane company regarding size and type of crane.
The steepness of the site should be taken into consideration. If the site is steep then a rough
terrain crane may have to be used.
All overhead electricity lines, trees, etc. will have to be considered when deciding the crane
position.
Care must be taken to ensure the safety of the public, site workers and contractors at all times.
8.10.4
Ultrafloor Beams
The Ultrafloor beams form the strength of the lost formwork system and therefore all due care
must be taken on site.
The Ultrafloor beams must be inspected on delivery for any sign of damage.
Damaged beams shall not be used without permission from the manufacturer.
Care must be taken to ensure that the beams are not damaged during erection. When
indicated on drawings, beams may be cut on site provided due care is taken to ensure
adequate bearing. A Partner saw with a 350mm diameter blade (or similar) is normally used
and the operator must be fully trained and experienced in the use of the cutting equipment.
Proper protection must be worn e.g. goggles, dust mask and ear muffs.
Except as noted above, cutting, drilling or modification of the Ultrafloor beams in any way shall
only be carried out with approval from the manufacturer.
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8.10.5
FC Formwork Sheet
Fibre-cement (FC) sheets are used as the permanent formwork infill boards between the
Ultrafloor beams.
The FC formboards have purpose-made directional strength properties and must always be
supported as indicated on the boards.
The FC formboards conform to AS 3610, the formwork code. The boards are strong enough to
take foot traffic and general construction loads as described in AS 3610. However, they are not
designed specifically to take impact load from heavy stepping, jumping or dropping of tools etc.
Prior to the shrinkage mesh being placed over the formwork, extreme care must be
taken when trafficking the boards.
The FC formboards must sit perfectly flat on the Ultrafloor beams. Any debris under the boards
may cause point loading and lead to failure of the board. Beam flanges should therefore be
thoroughly cleaned before installation of the boards.
The FC formboards must sit fully on the flanges of the beam i.e. a bearing width of at least
20mm.
Gaps up to 400mm between boards, and short sheets less than 500mm must be overlaid with
an oversized board that provides a minimum seating of 50mm each end onto the adjacent
sheet.
The formboards should never be placed across the beams and used as a footway.
The FC formboards can be cut on site. The most suitable cutting methods are score and snap,
an angle grinder with a diamond blade or circular saw with a HardiBlade.
Where the FC formboard is required to be set down in width for a set-down area these boards
must not be scored and snapped.
Never place a formboard with the end cantilevering over the end of the beams. However a
small projection in the order of 10mm is acceptable to support the edge boards for concreting.
Breathing in dust from silica-based products such as fibre-cement, clay and concrete is
hazardous. Over time, usually a number of years, this may result in lung cancer, bronchitis or
silicosis. Take care when cutting or drilling these products to minimise the amount of dust
generated and protect yourself by using personal protective equipment.
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8.10.6
Cranage
Chains should be used to crane Ultrafloor beams, FC formboards and any other components
from the truck. Note: Nylon straps are not to be used.
With care more than one beam can be craned off at a time.
Chains should be positioned approximately 300mm from each end and the beams lifted the
correct way up as shown in the diagram below.
8.10.7
Placing of Beams
The beams are placed on the support walls with proper bearing as indicated below:
Nominal Seating For Beams (mm)
Load Bearing Masonry
75
AAC & Low Strength Masonry
140
Concrete (precast)
60
Concrete (in-situ)
100
Steel
60
Ultrashell Bands
100
Bearers onto Piers
100
Beams are spaced apart to suit the FC formboards size. Available formboard widths are 350,
400, 450 and 500mm. It is recommended to cut a timber gauge rod for this purpose.
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8.10.8
Beam Layout
The position of the beams on the building is indicated on the Beam Layout Drawing. The mark
numbers of the beams are also shown on the drawing and indicate the type and length of the
beam. For this information, refer to the cutting/delivery schedule, which is always with the truck
driver. The ends of the beams are marked with the length or mark number.
Where multiple beams are placed under concentrated loads, care must be taken to ensure that
they are in the correct position.
8.10.9
Installation
Wherever there is a vertical drop in excess of 1.8m, the builder should have a perimeter
scaffold erected by a licensed contractor before placing Ultrafloor beams.
For additional protection, bunting or a temporary barrier may be placed at intermediate walls to
warn installers.
When installing beams start, if practical, from one end of the building. Two or three beams
should be placed in position either from scaffolding or ladders. The FC infill boards should then
be installed so as to create a safe working platform from which the installation can then
proceed.
Ideally there should be one man each end of the beam to place the beams and one man
placing the FC formboards so that a safe working platform is created.
Beams must never be lifted or handled manually as strain injury could result. Beams must
always be lifted and moved by crane. A crow bar or similar can be used for final adjustment of
the beam location.
As soon as there are a number of beams installed (say six), a load of FC formboards can be
lifted using chains. In all cases, packs of FC formboards should be placed at 90O to the
Ultrafloor beams with the face of the pack in line with the face of the support structure below.
The stacks should be a maximum of 50 sheets (600mm) high by 1.0m wide.
Heavy loads must not be placed part way across the Ultrafloor beam span.
The flanges of the beam must be clean before placing the FC formboards. The FC formboard
can be placed either way up. However, if the slab soffit is to be left exposed, the formboard
should be placed with the smooth side down and be neatly butted.
8.10.10 Mesh Reinforcement
Shrinkage control mesh sits directly on top of the Ultrafloor beams. Care should be taken when
handling the reinforcing mesh to avoid manual handling injuries and injury from sharp edges.
The reinforcing mesh over the Ultrafloor deck has a number of purposes, but primarily controls
shrinkage cracking. It also minimises any impact loading on the FC formboards after
installation is completed, and acts as a safety net to prevent construction personnel from
being able to fall through the deck in the event of an infill board being abused.
Page 8-25
ultrafloor
8.10.11 Working Underneath
Under no circumstances should any person be working in the floor area below an
Ultrafloor slab during any stage of the installation of the system or during the pouring of
the topping.
8.10.12 Propping
Centre propping of the beams is required in certain circumstances, as indicated on the

drawings. These frames or props must be in place prior to any beams being placed into
position.
A licensed and qualified person must install the props and check immediately before pouring
the slab.
It is vital that the span of these unpropped beams is such that there is adequate strength to
carry the loading imposed during the installation phase. This may include the weight of a pack
of formwork sheets.
In situations where centre-line propping is called up but is not in place prior to beam
installation the following maximum spans shall apply:
Beam Type
Maximum span during installation prior to

centreline propping being positioned
130R
5.0m
150R
6.5m
130C
6.5m
150C
8.0m
200C, 250C
10.0m
Note: Refer to Ultrafloor drawings for propping requirements prior to concrete pour.
8.10.13 Set-Down Clips
Set-down clips are used where the FC formboard is set down to the level of the Ultrafloor beam
soffit.
The maximum spacing of set-down clips is 330mm centre-to-centre. This equates to four equal
gaps along a full sheet 1380mm long.
Note that where two FC sheets adjoin each other, two clips should be place side by side so as
to support the edge of each sheet. The end of a sheet must never cantilever past a clip. It is not
appropriate for the ends of adjacent sheets to span onto the same clip.
Where there is a set-down at the end of a beam, the short length of FC formboard should be
located at two clip positions and at the support edge (ie 4 x SC1 clips or 2 x SC2 clips).
Furthermore, the FC sheet should be glued to the support edge to ensure that it is not
dislodged.
It is critical that the FC formboards fit exactly into the space between the Ultrafloor beams.
Page 8-26
ultrafloor
8.10.14 Multiformers
Multiformers are used where the area between the top of the wall and the underside of the
formboard needs to be enclosed.
The multiformers are folded down from the formboard to the support wall and glued and
stapled no more than 50mm from the top of the wall.
8.10.15 Steelwork
In many instances the structural steelwork elements required within the depth of the slab is
supplied by Ultrafloor. These items will be lifted by crane if necessary and directed into position
from ladders.
8.10.16 Penetrations
Soil/waste pipes etc should either be installed or clearly marked on support walls. In ground
floor situations, it is easier if the pipes are positioned prior to the Ultrafloor installation.
Ultrafloor beams can be closed up if necessary so that pipes come through the FC board.
Do not form holes through FC formwork sheets using aggressive methods as this may damage
the sheets.
Large rectangular openings can be made by scoring deeply around the perimeter of the
opening. Form a hole in the centre then saw cut from the centre toward the corner of the
opening. Tap waste pieces from the face side and clean rough edges with a rasp. Radius
corners with a half round rasp to eliminate stress points.
An alternative approach which is generally easier and safer is to form a polystyrene blockout
above the FC sheet in the location where the penetration is required. After the topping is cast
the full depth opening can be cut out.
Page 8-27
ultrafloor
8.10.17 Casting In-Situ Topping Concrete

!
FC formboards should be wetted down just prior to pouring concrete to avoid absorbing mix
water and to reduce the likelihood of drying shrinkage cracking.
Refer to notes on the drawings for further advice.
8.10.18 Stacking Materials on Slab
Stacking of materials on the slab should be avoided until at least 36 hours after pouring of the
concrete.
8.10.19 Off-Loading Materials onto the Ground
Dunnage should be positioned approximately 0.5m from each end. When stacking, the
dunnage should be in line. If the beams are long and the drawing shows centre propping, then
use centre dunnage.
8.10.20 Handing over the Ultrafloor Deck
Only Ultrafloor staff is permitted in the installation zone until the deck is finished and handed
over to the main contractor.
Shrinkage control mesh sits directly on top of the Ultrafloor beams. Care should be taken
when handling reinforcing mesh to avoid manual handling injuries and injuries from sharp
edges. The reinforcing mesh over the Ultrafloor deck has a number of purposes. Primarily it
contributes to the flexural strength of the floor and controls shrinkage cracking. However, it
also minimises any impact loading on the formwork sheet after installation is complete and acts
as a safety net to stop construction personnel from falling through in the event of the infill
board being abused. It is important that the main contractor is properly informed to place the
mesh in position prior to allowing access of other trades.
Page 8-28

Precast Conc Floor System

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ultrafloor

8.0 CONSTRUCTION INFORMATION

Support Structure Details

Figure 8.1.1a: Typical Ground Floor Bearer Detail

ULTRAFLOOR TECHNICAL MANUAL

September 2002 Edition

Figure 8.1.1b: Typical Ground Floor Balcony Detail

Figure 8.1.1c: Typical Ground Floor Ultrafloor Detail

ULTRAFLOOR TECHNICAL MANUAL

September 2002 Edition

Multi-storey construction can be divided into two broad categories:

Loadbearing wall construction

Lightweight concrete (aerated)

In-situ concrete frames

Precast concrete frames

Concrete band beams:

AAC & Low Strength Masonry

Bearers onto Piers

Some typical construction details follow:

ULTRAFLOOR TECHNICAL MANUAL

September 2002 Edition

Figure 8.1.2a: Typical Brickwork Support Detail

Figure 8.1.2b: Typical Concrete Blockwork Support Detail

ULTRAFLOOR TECHNICAL MANUAL

September 2002 Edition

Figure 8.1.2c: Typical Precast Wall Support Details

Steel Beam Supports

Figure 8.1.2d: Steel Beam Support Detail (Composite)

ULTRAFLOOR TECHNICAL MANUAL

September 2002 Edition

Figure 8.1.2e: Typical Steelwork Support Details 1

Figure 8.1.2f: Typical Steelwork Support Details 2

Figure 8.1.2g: Typical Steelwork Support Details 3

Reinforced Concrete Beam Supports

Figure 8.1.2h: Typical In-situ Concrete Support Detail

September 2002 Edition

Figure 8.1.2i: Typical Precast Concrete Support Detail

Propping Requirements During Construction

ULTRAFLOOR TECHNICAL MANUAL

September 2002 Edition

Trimming Voids / Saddle Supports

Figure 8.3a: Saddle Supports

ULTRAFLOOR TECHNICAL MANUAL

September 2002 Edition

Topping Slab Considerations

Lapping of Shrinkage Control Mesh

Case (a) Cross-wires have the same spacing.

Case (d) Cross-wires have differing spacing.

ULTRAFLOOR TECHNICAL MANUAL

September 2002 Edition

Stair to Ultrafloor Connection

Beams in line with stairs support wall under

Figure 8.4.2a: Typical Stair Detail

Beams in line with stairs saddle support and tang bars.

Figure 8.4.2b: Typical Stair Detail

ULTRAFLOOR TECHNICAL MANUAL

September 2002 Edition

Beams in line with stairs saddle support with holes.

Figure 8.4.2c: Typical Stair Detail

Wet Areas & Finished Floor Level Set-Downs

Figure 8.4.3a: Typical Wet Area Detail

ULTRAFLOOR TECHNICAL MANUAL

September 2002 Edition

Figure 8.4.3b: Typical Wet Area Set-Down Detail